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Thread: Ford Cortina Zetec Estate

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    Ford Cortina Zetec Estate

    Hello all,

    this is an story about my Mk1 estate Cortina. I bought this car end of -90. Below should be photo just after I bought it.



    First plan was to restore it as original as possible. I started by welding the rear end.



    At some point I opened the original engine. It was at very good condition. The seller told that engine has new pistons and bearings and so it was. After new paint engine looked like this



    After that I had some other Ford project and other things. This summer I wound this Cortina again and an litlle plan change. Inside my trailer looks like this.



    There is Volvo rear axle, sierra mt75 transmission and body part ( you know the thing over thansmission and some other ford parts. Engine is easy to move it has four tires.



    1,8 Mondeo 115hp silver top and running quite well. I have 2,0 camshaft and ecu. So there should be few hp more after those parts.

    Here is photo about the rear suspension. These are Passat parts



    Now the car is at garage and waiting for fitting the Volvo rear axle. In Finland we have strict regulations so I need to use for examble Volvo original support arms so hopefully those Volvo parts fits somehow to cortine frame. It is allowed weld new brackets to frame at least

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    Re: Ford Cortina Zetec Estate

    cool project...i like a mix of parts...cheers mark

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    Re: Ford Cortina Zetec Estate

    Nice start!

    I used the same Volvo axel on my Mk1 Cortina, but with a 4 link.

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    Re: Ford Cortina Zetec Estate

    Nice start!

    I used the same Volvo axel on my Mk1 Cortina, but with a 4 link.

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    Re: Ford Cortina Zetec Estate

    Thanks this will be an slowly processing project but some day it will be ready at least I hope so. I am novice with zetec technic and also technical English so you are allowed to enjoy reading my story

    MK2 diesel or v6 Mondeo rear disk bakes should fit quite easily to Volvo rear axel. I do not have those mondeo calipers or disks so I need to search from ebay. Volvo has 5x108 bolt pattern so I need to drill only three new bolt holes.

    I have couple of question now and most likely much more in future

    My Zetec has plastic inlet manifold. It seems to turn down and goes quite low. I was just wondering is there space for RWD engine mounts with the plastic inlet manifold? What is your inlet manifold recommendations for almost original setup?

    Exhaust manifold is other open issue at this moment. What is your recommendation for MK1 Zetec Cortina? Escort exhaust manifold should fit quite well if I have understood right.

    Thank you in advance.

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    Re: Ford Cortina Zetec Estate

    i think some use the escort zetec alloy inlet to allow more space and i think the escort ashley manifold may fit ?

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    Re: Ford Cortina Zetec Estate

    Thanks for the information. Ashley should be good solution. We are driving from the co-driver side so steering column is on the exhaust side.

    I managed to pull the Volvo rear axle to garage. After first look there some challenges to use those passat springs because frame is just over the spring area. Most likely I need to change plans. Leaf springs is the easiest way. To get my car road legal I have to install Lotus cortina type tramp bars if I use leaf springs. Could someone have inform the bar length just for possible future need?

    Here some photos about the rear axle under car. Volvo links could be possible to use.







    Here is photo with the Sierra plate. I might need to use automatic transmission because I am missing one pedal



    This will proceed some day in future.

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    Re: Ford Cortina Zetec Estate

    are you allowed to move the locating brackets on the axle to line up with your chassis...its just grind and weld...no one will notice..!!!!.
    Job done...
    Still like the idea...cheers mark

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    Re: Ford Cortina Zetec Estate

    Axle and frame brackets are allowed to move and make own. Links or arms must be from some +100hp car. I need to use Lotus Cortina parst or some other car part that has same or higher amount of hp. Volvo and Sierra parts are easy to find so that is the reason for my choose.

    Is there some build thread about spring change for mk1 cortina. I would like to see how the upper bracket is made and where is it welded. I think that this estate has differend kind frame than sedan.

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    Re: Ford Cortina Zetec Estate

    Most times you would make a turret for your spring.usually on the wheel arch..then match the bracket on the axle..has the Volvo axle got a panard rod.use that

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    Re: Ford Cortina Zetec Estate

    Thanks for the reply. I found MK1 Cortina project where has been used similar type of springs. Springs was at front of the axle and turrets was added. Volvo arm has place for shock absorber. Here is photo where spring is at original shock absorber place.





    It seem that there is enough space for spring. How much should there be space at frame and wheel side? Length from center of axle to center of spring is about 160mm. I was just wondering is it too much? Maybe I could use that distance if I change the spring compression rate if needed ( you know the wire features). Actually I do not even know what springs I have at the moment.

    Here is photos about the arm placements.





    It seems that I could use the original bracket with the lower arm. I just need to cut a little bit from the floor or just weld the bracket below Cortina original frame. If I do that the arm is not the lowest point of the rear axle. Situation and plans changes every time I went to garage. Upper arm should be easier. Just drill hole to frame. It seems that I need to flip the upper arm at the inner side of the original Volvo bracket and cut and weld the brake side bracket back at the diff side. With this change upper arms width will be narrower. Not easy to understand but I can give you more specific information with Finnish language

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    Re: Ford Cortina Zetec Estate

    And yes volvo axle has panhard rod. I forgot to answer. Bracket for that should be easy to make.

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    Re: Ford Cortina Zetec Estate

    Here is photo about the upper arm idea.





    Next I will order new bushings and fix the axle place so that I could start bracket designing.

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    Re: Ford Cortina Zetec Estate

    Here is photo about the upper arm idea. Next I will order new bushings and fix the axle place so that I could start bracket designing.

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    Re: Ford Cortina Zetec Estate

    Hello,

    pushing project started. All other are removed only axle pushings are left. I made some kind of tooling today and hopefully tomorrow have some time to try it. I have also Ashley exhaust manifold now.



    Beginning of this year I modified electric scooter to fit to my child. Now it is almost ready so I can focus more to Cortina.
    Last edited by Deluxe66; 10-02-2018 at 21:25.

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    Re: Ford Cortina Zetec Estate

    Are you using the Volvo axel link arms? Are you finding the axel a bit wide for the Cortina or will you be narrowing it?

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    Re: Ford Cortina Zetec Estate

    Yes I at this monent original volvo arms will be used. Lower arm is quite long but hopefully it is able to use.

    Actually I do not know is the axle too wide. Accordimg the specs volvo axle is "only" 90mm wider than cortina. I am hoping that volvo axle will fit choosing the correct offset rims.

    Did you use original volvo axle?

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    Re: Ford Cortina Zetec Estate

    Hello, I have done at least something to this Cortina project. I was not planned to take engine out off the Mondeo but my bouys tear down the car almost completely. So it is better to take all important parts and give it to recyclist.

    Ones again SJ was good tool to have.



    I have also installed i-beam to garage. It took only ten years to install

    I have an guestion about the engine management wiring. I have taken off all unneccesary wiring and managed to start the engine. There is few diodes that I did not used at all. Are those neccesary to use?

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    Re: Ford Cortina Zetec Estate

    Now the engine and transmission are nearly at final place.





    It seems that transmission tunnelr needs only small modification. MT75 is not so wide and lenght is Not an issue at all. That hole might be the only cut for the tunnel. At this moment I will not use the Sierra tunnel at all.

    I installed also the exhaust manifold. It seems that if I tilt or turn the engine few degrees to inlet manifold side I am able to use original steering parts also. I have bought the Mk 2 Escort steering parts also. Maybe I use those I do not know yet.

    This project will continue sooner or later. My oldest son is now 9 years and I hope this is ready before he gets driving lisence 2017.

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    Re: Ford Cortina Zetec Estate

    glad to see progress and hopefully you will be ready before your sone can legally drive it

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    Re: Ford Cortina Zetec Estate

    For serviceability in the future, is there enough room in the tunnel to pull the gearbox off the motor without taking the engine out as well?

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    Re: Ford Cortina Zetec Estate

    Well ready before 2017 might be impossible so next goal is 2027

    Most likely I need to lower the engine, crossmember and transmission to be able to take off only transmission. I have the transmission cover from Sierra but I am not decided will I change the tunnel or not.

    At the moment I am trying to decide the engine place. I have bolted the mk2 escort crossmember and also escort rack & pinion. Situation looks like this at the moment.





    It is quite clear that mk2 escort steering collumn is not useful. Only if I drill holes to exhaust

    I have suzuki swift rack & pinion and width is quite same. There is two benefits on that suzuki steering. The steering collumn shaft is on angle and this is placed behind the crossmember.

    Is there some guides where I can read different option for steering? What rack & pinions yuo have used on mk1 cortinas.

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    Re: Ford Cortina Zetec Estate

    After some day looking under the bonnet I decided to use the original steering. It seems that all fits under the bonnet. I need to order the RWD thermostat housing /adapter. Engine is now moved as back as possible. There is about inch clearance between exhaust and brake booster. Engine is about half inch at inlet manifold side.

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    Re: Ford Cortina Zetec Estate

    Is the engine moved back - with - the thermo conversion added or not? It adds between 25 - 40mm depth to the back of the head + you should allow for some rocking on the mounts also gearbox / propshaft realignment / fiddle room.

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    Re: Ford Cortina Zetec Estate

    There is about 50mm space for the thermostat conversion kit. Below is few photos about the space for the gearbox. I think that is enough space otherwice that between the exhaust and steering box. I have now made some kind of engine mountings to be able to proceed and test fit all other parts.








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    Re: Ford Cortina Zetec Estate

    Some progress after long time.

    I had an little helper before Christmas. Together we managed to update the intake system.




    Alternator is also installed. I have Zetec Escort water pump an pulley. It seems that Mondeo original tensioner should work. Belt is from some fiat lenght was 1085mm if I remember right.



    Transmission tunnel is also almost ready. It is point welded in place after this photo.



    I will weld these L shape bars for strengthen the tunnel and also there is good place for transmission installation.



    My friend advised and shop from Finland where I can bought road legal 4 link bars with even my own lengths. Could someone recommend the bar lengths for Estate Cortina MK1.

    I wonder that RWD Escort bar lengths should be ok but if someone has better suitable lengths for Cortina please inform.

    I have the Volvo panhard bar so I can use that if needed.

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    Re: Ford Cortina Zetec Estate

    You made some good progress here. I like your little helper!
    I used the same Volvo axel on my Cortina mk1 project. I used four links and panhard rod, but I don't think my measurments will be any good for you, as I have a completely new fabricated floor and chassis.
    I think you may be best to use the standard four link lengths from the Escort kits. You may even be able to use their floor mounting boxes with some modification. With panhard rods, I like to keep them as long as possible, and mount as close to horrizontal as possible at ordinary ride height.
    Will you be using the Volvo handbrake mechanism? Its a nice set up.

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    Re: Ford Cortina Zetec Estate

    Thanks most likely I will use v6 mondeo rear calibers.

    Did you use original width volvo axle on your Cortina?

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    Re: Ford Cortina Zetec Estate

    Quote Originally Posted by Deluxe66 View Post
    Thanks most likely I will use v6 mondeo rear calibers.

    Did you use original width volvo axle on your Cortina?
    No. I was lucky enough to find one for sale that had already been narrowed. The axle tubes were cut and shut, and the half shafts cut and re-splined.

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    Re: Ford Cortina Zetec Estate

    Now I have done something to my Cortina. I am have managed to get transmission bracket and also beginning of exhaust.

















    I have ordered digital angle meter from china. It has been very useful. I do not know where to measure correctly but measured from the belt engine close enough straight.

    I welded those round tubes to the L-shabe beams. Now I was able to turn the car around. Next project is rear axle. I will start narrowing the volvo axle.

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    Re: Ford Cortina Zetec Estate

    wow, i thought it was a new topic started, but almost 2 years on one page already

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    Re: Ford Cortina Zetec Estate

    Well during these last two years I have made more than I expected. I welded the rear end maybe 1999 and started this project again 2017. My next goal is get this ready end of 2027 before my son is 18 years.

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